Method for manufacturing electrical components with spiral windings and winding machine

Abstract

A method and an automatic winding machine for manufacturing an electrical component having a support having at least one winding of a conductive wire are described. The winding extends in a spiral manner, but the conductive wire on which the winding is made is not twisted. It is provided to rotate the support on its axis, while simultaneously pressing the conductive wire into a slot in the support by a pressing roller rolling on a slot. The pressing roller is guided by a wire guide flange that controls its displacement so that the pressing roller captures and moves across the entire slot. In one embodiment, the electrical component has a first winding on the front side of the support and a second winding on the rear side of the support. The two windings are made of the same wire and overlap the periphery of the support. The pressing roller is displaced from the front side to the rear side to perform the insertion of the wire into the slot of the second winding by using the second wire guide flange as a guide.

Description

Technical Field

[0001] The present invention relates to a method and a winding machine for manufacturing an electrical component comprising at least one winding of a helically extending conductive wire.

Background Art

[0002] Some electrical components include a support made of metal or plastic that houses windings of at least one conductive wire, for example copper wires arranged in a spiral.

[0003] For example, WO2022 / 136548 describes a rotary induction transformer comprising a synchronous electrical machine, particularly a ferrite toroidal core, a primary winding housed within the toroidal core, and a secondary winding arranged on a flat rotor, the primary winding and the secondary winding being inductively coupled. Both windings are helical and the rotor is provided coaxially with respect to the toroidal core, so that the secondary winding of the rotor and the primary winding of the toroidal core are located on parallel planes arranged at a certain axial distance. The flat rotor is a disk made of a plastic material and the secondary winding is inserted or embedded in the material of the rotor.

[0004] Further applications of flat supports with helical windings are known, for example in the fields of the sensor industry, measuring tools, etc.

[0005] The present invention relates to a method and a machine for manufacturing flat, convex and conical supports having at least one helical winding on one side of the support, regardless of the intended use of the support on which the winding is applied.

[0006] This type of winding may seem achievable without difficulty at first glance, but in fact there are problems.

[0007] For example, when using a needle winding machine to deposit conductive wire on a flat support in a spiral trajectory while rotating the support, or when rotating the wire guide needle of the winding machine along a spiral path, the conductive wire tends to twist and detach from the support.

[0008] While it is possible to automate the winding of conductive wires or bundles of conductive wires to create spirally extending windings, the need to simultaneously avoid the drawback of inducing stress in the conductive wires or bundles of conductive wires remains. These stresses can cause the windings to detach from the support.

[0009] DE1281030B describes a method for winding a single conductive wire onto a smooth cylindrical support without slots or grooves, the support being separated by two flanges. The winding method provides the use of a pressing roller, indicated by reference numeral 20 in the figure, as well as restraining rollers 8 and 9 intended to roll on the surface of the smooth cylindrical support. The conductive wire is wound onto the cylindrical surface to form a precisely cylindrical coil, such that all loops have the same diameter and each loop remains in shoulder-to-shoulder contact with adjacent loops.

[0010] EP2266193B1 describes a method for winding conductive wire onto a substantially cylindrical coil support, the support having a smooth outer surface without slots or grooves between two flanges. The method provides the use of a winding machine equipped with means for rotating a coil holder relative to a wire supply element, so that all loops are of the same diameter for winding the wire onto the coil holder. The wire extending from the distribution element to the coil holder has an angular direction with respect to the outlet of the distribution element. In one embodiment, the machine provides means for rotating the coil holder relative to the distribution element for winding the wire onto the coil holder, and a pressing roller for applying pressure to the portion of wire wound on the coil holder. During winding, the pressing roller applies pressure to the wire in a direction not perpendicular to the surface on which the wire is wound. [Overview of the project]

[0011] The object of the present invention is to provide a method and winding machine for automatically and reliably manufacturing an electrical component having a support having at least one winding of a helically extending conductive wire, particularly without twisting the conductive wire.

[0012] A further object of the present invention is to provide a method and winding machine for manufacturing an electrical component having a support having two sides, wherein at least one helical winding is present on each side.

[0013] A first aspect of the present invention relates to the method of claim 1 for manufacturing an electrical component comprising a support, i.e., a body having at least one side, wherein the side has at least one slot that is coaxial with the axis X of the support and extends radially or mainly radially (i.e., the radial component is significantly higher than the axial component) and has a helical shape, and at least one conductive wire defining a helical winding is housed in the slot.

[0014] This method includes: A) Rotating the support on axis X so as to rotate the slot intended to accommodate the conductive wire, B) Supplying conductive wires to the support near the slot, C) Inserting a conductive wire into a slot by a pressing roller positioned to roll on a slot having a rotation axis that transverses, preferably intersects with, the axis X of the support, and moving the pressing roller radially with respect to the axis X of the support, toward or away from it, thereby moving along the entire length of the slot while the conductive wire enters the slot under the thrust applied by the pressing roller.

[0015] The described method makes it possible to overcome problems related to the twisting of conductive wires. In fact, by providing rotation of the slot through the rotation of the support on axis X, and not rotation of the conductive wire (on axis X or on itself), it is achieved that the conductive wire can be inserted into the slot without twisting it. In fact, the conductive wire can be fed continuously between the pressing roller and the slot, for example along a straight path tangent to the slot, without twisting or rotation, regardless of the shape of the wire, i.e., the shape of its cross-section.

[0016] In other words, the support rotates on axis X, while the wire remains fixed in contact with the slot on the same axis X, but moves forward along its length to be inserted into the slot.

[0017] This arrangement allows for the creation of high-quality, durable windings on the support, as there is no risk of the conductive wire detaching from the support while the electrical components are in use, due to internal stress caused by the initial twisting of the conductive wire itself.

[0018] For the purposes of this invention, the expression "spiral winding" refers to a radial or primarily radial layered winding in which conductive wires are layered to increase the diameter of the winding. This excludes coil windings of a constant diameter. Radial layering is always achieved when the support is flat, and primarily radial layering is always achieved when the support is not flat, for example, conical.

[0019] For simplicity, conductive wires are hereafter simply defined as "wires." It should be noted that the term "wire" is used to refer to both individual conductive wires and Litz wires, i.e., strands of conductive wires, and bundles of parallel conductive wires that may be pre-pressed and carburized or wound on tape. Furthermore, the term "wire" is used indiscriminately to refer to any of the above wire types, regardless of the cross-section of the wire, which may be, for example, circular, square, or rectangular.

[0020] Preferably, phase A is performed by locking the support on a drive shaft that is coaxial with axis X and susceptible to rotation around axis X.

[0021] Preferably, phase B is performed by a wire guide tube that is movable on at least three axes relative to the support and directional relative to the support, and care is taken to supply the wire to each slot in a trajectory tangent to the slot. In this way, the insertion of the wire into the slot by the pressure roller is performed without inducing twisting in the wire.

[0022] Preferably, phase C is performed by bringing the pressure roller into contact with a wire guide flange that acts as an end stop or cam and sets the distance between the pressure roller and the axis X of the support. In this way, the pressure roller is guided by the wire guide flange and moves along the entire length of the slot while rolling along it without skidding. The wire guide flange is formed to always hold and guide the pressure roller in a position corresponding to the slot that moves beneath the pressure roller itself due to the effect of rotation given to the support.

[0023] Preferably, the wire guide flange is also positioned coaxially with respect to the axis X of the support and is rotatable on the same axis X. The wire guide flange is spiral or helical and has a side surface extending between the minimum diameter portion and the maximum diameter portion. Whenever the pressure roller is in contact with the side surface of the wire guide flange at the minimum diameter portion, the pressure roller is at the minimum distance from the axis X of the support, for example, at the first end of the slot, which is the beginning of the slot. Whenever the roller is in contact with the side surface of the wire guide flange at the maximum diameter portion, the pressure roller is at the maximum distance from the axis X of the support, for example, at the second end of the slot, which is the end of the slot. In practice, even when the pressure roller is provided on a numerically controlled unit, for example with movement on three axes, the wire guide flange ensures that the pressure roller always moves along the slot.

[0024] Preferably, the spirally extending slot has a shape complementary to the wire cross-section, and the wire is inserted by interference. More preferably, the wires inserted into the slot have slightly spaced loops that do not touch each other. Exactly, this is because the slot has its own width.

[0025] This method is preferably carried out by providing a relative rotation between these elements, thereby keeping the side surface of the wire guiding flange in the pressing roller axially aligned with the slot.

[0026] Thus, the rotation of the wire guiding flange on the axis X of the support is controlled according to one of the following methods: - Rotate the wire guiding flange slower than the support, or - Rotate the wire guiding flange at the same speed as the support but with an intermittent movement, such that the support and the wire guiding flange rotate at the same speed on the axis X for a certain time interval, and while the support continues to rotate, the wire guiding flange remains fixed for other time intervals.

[0027] Preferably, the electrical component has a first winding and a second winding arranged on opposite parts of the support. The support is flat and has a front side and a back side. The first slot of the first winding is on the front side, and the second slot of the second winding is on the back side. The support has a transition zone where the first slot merges with the second slot around the circular sector of the support. Phase C is executed with this configuration: C1) Insert the wire into the first slot by means of the pressing roller and move the pressing roller radially with respect to the axis X of the support, between a proximal position with respect to the axis X (the start of the first slot) and a distal position with respect to the axis X (the end of the first slot), thereby obtaining the first winding. C2) Lay the wire on the edge of the support in the transition zone and guide the wire from the front side to the back side of the support. C3) Insert the wire into the second slot by means of a pressing roller and move the pressing roller radially with respect to the axis X of the support between a position distal with respect to the axis X (start of the second slot) and a position proximal with respect to the axis X (end of the second slot) to obtain the second winding.

[0028] In practice, whenever the support has two opposite flat sides, the first winding is obtained by starting the insertion from the central zone on the front side of the support and moving the pressing roller towards the periphery on the front side of the support itself. This involves the above-mentioned radial movement induced by the wire guiding flange. The second winding is achieved by starting the insertion from the peripheral zone on the back side of the support and moving the pressing roller towards the central zone on the back side of the support itself. The wire is overlapped on the edge of the support in the transition zone so that the first and second windings can be made with the same wire.

[0029] More specifically, phase C1 is carried out by inducing the radial movement of the pressing roller with the first wire guiding flange, C2 is carried out by using a wire guiding tube movable and orientable with respect to the support, and C3 is carried out by inducing the radial movement of the pressing roller with the second wire guiding flange. Both wire guiding flanges are coaxial with respect to the axis X of the support and are located on opposite sides with respect to the axis X. Relative rotation is provided between the support and each wire guiding flange between phases C1 and C3. This is done as described above, i.e., at different rotational speeds or with an intermittent movement of the wire guiding flange.

[0030] Preferably, the electrical component has two terminals, i.e., the two ends of the wire protruding cantilever-like from the support. To automatically obtain the two terminals, each slot preferably has a radial segment with respect to the axis X of the support, and the insertion of the wire into the radial segment is carried out as follows: D) The support is locked with respect to axis X, the pressure roller is aligned with axis X, and the pressure roller is moved radially by rolling it on the radial segment of the slot, keeping the axis of rotation of the pressure roller and axis X in a parallel plane.

[0031] Once the wire is inserted into the radial segment of the slot, the ends of the wire are pulled and cantilevered outwards from the support, and then cut to a predetermined size.

[0032] A second aspect of the present invention relates to an electrical component directly obtained by the method described above.

[0033] The electrical component includes a support or body having at least one side, preferably two opposing sides, on which at least one helical slot is present, coaxial with the axis X of the support. Conductive wires defining the helical winding are housed within the at least one slot.

[0034] By the method described, a conductive wire with one helical winding, or a conductive wire with multiple helical windings, is not twisted and therefore does not have internal stress.

[0035] The wires inserted into the spiral slots are stacked substantially radially or primarily radially, and not axially, and therefore the loops defined by the wires have a minimum diameter and a maximum diameter.

[0036] As described above, the support is preferably flat, for example, circular or disk-shaped, and has a first winding on the front side and a second winding on the back side. The windings have terminals that cantilever out from the same side of the support, for example, only from the back side.

[0037] A further aspect of the present invention relates to an automatic winding machine for manufacturing the above-mentioned electrical components.

[0038] The winding machine includes a work station and a supply unit, the latter configured to supply conductive wire to the work station. The work station includes a first spindle, preferably a corresponding first drive shaft fixed to a frame, means for restraining a support for electrical components coaxially with the drive shaft, a first wire guide flange and a pressing roller.

[0039] The support for the electrical components and the first drive shaft are rotatable around the axis X of the support.

[0040] The pressure roller can be positioned relative to one side of the support so that it can roll on at least one slot and is susceptible to radial displacement with respect to the axis X of the support of the electrical component. The first wire guide flange is mounted coaxially with the first drive shaft and is susceptible to translational effects between a proximal and distal position relative to the support along the first drive shaft. Furthermore, the first wire guide flange is susceptible to synchronous rotation with the first drive shaft and / or relative rotation with respect to the first drive shaft.

[0041] The first wire guide flange is spiral or helical in shape, and the insertion of the wire into the slot is performed by rotating the first drive shaft together with the support of the electrical component, causing the pressure roller to roll on the slot, and simultaneously pushing the wire into the slot. Radial movement of the support relative to axis X is given to the pressure roller, causing it to follow the slot, i.e., to roll on the slot. This radial movement is guided by the side surface of the first wire guide flange, which acts as a cam for the pressure roller, and the pressure roller follows its profile.

[0042] Preferably, phase A of the method is performed by a first spindle and a first drive shaft, phase B of the method is performed by a supply unit, and phase C of the method is performed by rolling the press roller over the entire length of the slot with the wire inserted between the slot and the press roller, and translating the press roller radially with respect to axis X on the support of the electrical component.

[0043] Preferably, the supply unit includes a wire guide tube that is movable with respect to axis X and shared by a support for electrical components and a first drive shaft. The wire guide tube is also directional with respect to a support provided on the first drive shaft and supplies wire perpendicular to the sides of the support and / or radially or tangentially to the slot. For example, the wire guide tube can be mounted on a numerically controlled manipulator or a machine having three axes.

[0044] In one embodiment, the means for constraining a support coaxially with a drive shaft includes two levers pivotally mounted on the head of a first drive shaft and operable to engage with the inner edge of the support. For example, a support for an electrical component has a central hole coaxial with axis X, and the levers located on the first drive shaft are operable to engage with the central hole of the support. A control rod for controlling the levers is coaxially housed within the first drive shaft and is translationally movable between a retracted position and an extended position. In the retracted position, the control rod does not engage with the levers, and the levers engage with the support and constrain it on the first drive shaft (normally the closed position). In the extended position, the control rod is inserted between the levers, and the levers are disengaged from the support.

[0045] The work station preferably includes a first flange-retaining carriage into which a first drive shaft is inserted. A first wire guide flange is provided on the first flange-retaining carriage and is provided with a corresponding actuator that controls the rotation of the first wire guide flange independently of the rotation given to the first drive shaft by a first spindle. The first flange-retaining carriage is translatable along the first drive shaft between a retracted position and an advanced position. In the retracted position, the first wire guide flange is away from the support of the electrical component constrained on the first drive shaft. In the advanced position, the first wire guide flange is in contact with the support constrained on the first drive shaft. Clearly, the first drive shaft is rotatable within the first flange-retaining carriage.

[0046] The side surface of the first wire guide flange preferably extends between the minimum diameter portion and the maximum diameter portion. As described above, the side surface of the first wire guide flange defines the end stop in the radial displacement of the pressing roller with respect to the axis X of the support.

[0047] The winding machine preferably includes a unit configured to guide and insert a wire into a slot in a support. A pressing roller is provided on such a unit, which is susceptible to displacement on at least three axes, enabling the pressing roller to be inserted between the first wire guide flange and the support, with the axis of rotation of the pressing roller transverse, preferably intersecting, the axis X of the support and the first drive shaft. The unit preferably includes an arm, on which the pressing roller is provided. The arm is movable to keep the pressing roller in contact with the side of the first wire guide flange during rotation of the first wire guide flange.

[0048] The winding machine preferably further includes a pincer assembly that is movable relative to an axis Y perpendicular to axis X, or relative to both axis X and axis Y, and is operable to cut wires at terminals.

[0049] One embodiment of the winding machine is configured to manufacture an electrical component having two windings on opposite sides of a support. In this configuration, the spindle is fixed, and the winding machine further includes a second spindle defined as a tailstock spindle, a corresponding second drive shaft, and a second wire guide flange. The tailstock spindle, the second drive shaft, and the second wire guide flange are located opposite the first spindle, the first drive shaft, and the first wire guide flange, respectively, with respect to the support constrained to the first drive shaft. The first and second drive shafts are coaxial with respect to the axis X of the support and are rotatable about the same axis, and the second drive shaft is translatable along axis X between a forward position and a retracted position. In the forward position, the second drive shaft abuts against the support constrained to the first drive shaft and / or directly abuts against the second drive shaft. In the retracted position, the second drive shaft is away from the support constrained to the first drive shaft, and a gap is defined between the support and the second drive shaft into which a pincer assembly can be inserted in addition to the feed unit and pressure rollers.

[0050] The second wire guide flange is mounted coaxially with the second drive shaft and is susceptible to translational influences between a proximal and distal position relative to the back side of the support on the second drive shaft, and is susceptible to synchronous rotation with the second drive shaft and / or relative rotation with respect to the second drive shaft. In practice, the two wire guide flanges can be positioned opposite each other with respect to the support of the electrical components. Both flanges are rotatable independently of each other and under laws of motion independent of each drive shaft.

[0051] In this embodiment of the winding machine, the work station includes a second flange-holding carriage into which a second drive shaft is inserted and which rotates freely. A second wire guide flange is mounted on the second flange-holding carriage and is provided with a corresponding actuator that controls the rotation of the second wire guide flange independently of the rotation given to the second drive shaft by the tailstock spindle. The second flange-holding carriage is translatable along the second drive shaft between a retracted position and a forward position. In the retracted position, the second wire guide flange is away from the support constrained on the first drive shaft. In the forward position, the second wire guide flange abuts against the rear side of the support constrained on the first drive shaft, on the side opposite to the side from which the first wire guide flange operates.

[0052] For example, whenever the first and second windings are identical, the work station can always be configured in a mirror image configuration with respect to the support of the electrical components. That is, the first spindle, first drive shaft, and first wire guide flange are on the front side of the support, and the tailstock spindle, second drive shaft, and second wire guide flange are on the rear side of the support, and the two wire guide flanges are substantially the same shape.

[0053] Generally, however, the second wire guide flange has a helical or spiral shape that is the same as or different from that of the first wire guide flange.

[0054] The insertion of the wire into the slot on the back side of the support is performed by rotating the second drive shaft together with the support and the first drive shaft, causing the pressure roller to roll on the slot and pushing the wire into the slot, thereby giving the pressure roller radial movement relative to the axis X of the support. Similar to the first winding as described above, the radial movement of the pressure roller is guided by the side of the second wire guide flange to obtain the second winding.

[0055] The sides of the second wire guide flange also extend between the minimum diameter portion and the maximum diameter portion. The sides of the second wire guide flange function as end stops in the radial displacement of the pressing roller relative to the axis X of the support.

[0056] In this embodiment of the automatic winding machine: -Phase A of the method is performed by rotating the assembly formed by the first spindle and the first drive shaft, the tailstock spindle and the second drive shaft, and the support for the electrical components. -Phase B of the method is performed in the machine's supply unit, Phase C of the method is performed by rolling the pressure roller over the entire length of the slot on the back side of the support with the wire inserted between the slot and the pressure roller, thereby translating the pressure roller radially on the support with respect to its axis.

[0057] The second winding is created after the first winding is made. The supply unit is movable to overlap the wires on the support and position them between the end of the first winding and the beginning of the second winding.

[0058] The automatic winding machine preferably includes a gripper configured to restrain the terminals of conductive wires at the head of a second drive shaft. For example, the gripper can be made integrated with the second drive shaft and includes jaws and a control shaft provided on the second drive shaft. The control shaft is located within the second drive shaft and coaxial with it, and is susceptible to translational effects on axis X. The jaws are movable to move toward and away from each other in response to stresses applied by the control shaft, restraining and releasing the terminals of wires that cantilever from a support or pass through holes in the support.

[0059] As described in the method, each wire guide flange of the automatic winding machine is rotated by its actuator at a rotational speed lower than the rotational speed of each drive shaft, or driven at the same rotational speed in an intermittent motion, so that the pressing rollers engage the slots. [Brief explanation of the drawing]

[0060] Further features and advantages will become clearer from the description of several preferred but non-exclusive embodiments of the method for manufacturing a stator, which are illustrated illustrative and non-limiting with reference to the accompanying drawings: [Figure 1] Figure 1 is a rear perspective view of an electrical component directly obtained by the method according to the present invention. [Figure 2] Figure 2 is a front elevation view of the electrical component shown in Figure 1. [Figure 3] Figure 3 is a cross-sectional view of the electrical component shown in Figure 1, considered on the diametrical plane. [Figure 4] Figure 4 is a left-front perspective view of the first configuration of the winding machine according to the present invention. [Figure 5] Figure 5 is an enlarged view of the winding machine shown in Figure 4, and in particular shows the work station for creating spiral windings on a support for electrical components. [Figure 6] Figure 6 is an enlarged view of the winding machine shown in Figure 4, and in particular, a view of the front right of the work station. [Figure 7A] Figure 7A is an enlarged view of the winding machine shown in Figure 4, specifically from a view looking to the right and forward of the work station. [Figure 7B] Figure 7B is an axial cross-sectional view of the winding machine work station shown in Figure 4, considered in a vertical plane. [Figure 8A] Figure 8A is a right-hand perspective view of the work station in the second configuration of the winding machine shown in Figure 4. [Figure 8B] Figure 8B is an axial cross-sectional view of the winding machine work station shown in the configuration of Figure 8A, considered in a vertical plane. [Figure 8C] Figure 8C is a left-front perspective view of the second configuration of the winding machine work station shown in Figure 4. [Figure 9] Figure 9 is an axial cross-sectional view of the winding machine work station shown in Figure 4, considered in the vertical plane in the third configuration. [Figure 10]Figure 10 is a right-front perspective view of a third configuration of a part of the winding machine work station shown in Figure 4. [Figure 11] Figure 11 is a top and partially rear perspective view of a fourth configuration of the winding machine work station shown in Figure 4. [Figure 12] Figure 12 is a schematic elevation view of the electrical components and a portion of the winding machine work station shown in Figure 4 at three consecutive points in time during the process of creating a helical winding. [Figure 13] Figure 13 is a front elevation view of a fifth configuration of a part of the winding machine work station shown in Figure 4. [Figure 14] Figure 14 is a left-front perspective view of the fifth configuration of a part of the winding machine work station shown in Figure 4. [Figure 15] Figure 15 is a left-front perspective view of a sixth configuration of a part of the winding machine work station shown in Figure 4. [Figure 16] Figure 16 is a rear and top perspective view of a portion of the winding machine work station shown in Figure 4, at a point following the sixth configuration for completing the electrical components. [Figure 17] Figure 17 is a rear and top perspective view of a portion of the winding machine work station shown in Figure 4, at a point following the sixth configuration for completing the electrical components. [Figure 18] Figure 18 is a left front perspective view of a portion of the winding machine work station shown in Figure 4, with an automatic pincer being inserted to cut conductive wires. [Figure 19] Figure 19 is an axial cross-sectional view taken on a vertical plane of the winding machine work station shown in Figure 4, in which an automatic pincer is being inserted to cut conductive wires. [Figure 20] Figure 20 is a front and left perspective view of a portion of the winding machine work station shown in Figure 4, with the completed electrical components ready for removal. Detailed description of the invention

[0061] Figures 1-3 show electrical component 1 obtained by the method according to the present invention, and the method will be described below.

[0062] In particular, Figure 1 is a rear perspective view, Figure 2 is a front elevation view, and Figure 3 is a diameter cross-sectional view considered on a vertical plane containing axis X of electrical component 1.

[0063] The electrical component 1 includes a support 2 on which at least one winding 3', 3'' of a conductive wire 4 is present. In the example shown in the figure, the support 2 is circular, substantially flat, and disk-shaped, having a front side 2' and a back side 2'' and a central through hole 5.

[0064] On at least one, preferably both, of the two sides 2' and 2'', the support 2 has at least one slot 6', 6'' (Figure 3) having a helical pattern intended to accommodate the corresponding windings 3', 3''. In the example shown in the figure, the support 2 has a helical slot 6' on the front side 2' where the primary winding 3' is accommodated, and a helical slot 6'' on the rear side 2'' where the secondary winding 3'' is accommodated.

[0065] Slots 6 and 6' having a helical pattern have a radial extension with increasing diameter, having an initial segment with a minimum diameter and a terminal segment with a maximum diameter. To obtain windings 3', 3'', the conductive wires 4 are stacked radially with respect to the axis X. If the support 2 is not flat, for example, conical or rounded, the conductive wires 4 are stacked mainly radially with respect to the axis X to obtain windings 3', 3''.

[0066] The first winding 3' and the second winding 3'' can each be made of a conductive wire 4, or a strand of conductive wires 4, such as Litz wire, or a bundle of parallel conductive wires that have been pre-pressed and carburized to maintain their initial orderly arrangement.

[0067] In Example 1 shown in the figure, the two windings 3' and 3'' are obtained by housing a single Litz conductive wire 4 in slots 6' and 6'', in particular, which transitions from the front side 2' to the back side 2'' in the transition zone 7 between the two slots 6' and 6''. Thus, the same wire 4 is first wound around one side 2', 2'' and then around the other side 2'', 2', transitioning in the transition zone 7. In the transition zone 7, the first winding 3' transitions from the front side 2' to the back side 2'' and becomes the second winding 3''. In practice, the transition zone is at the peripheral edge of the support 2, and is a groove or cut formed circumferentially on the peripheral edge of the support 2.

[0068] In the example shown, the Litz conductive wire 4, hereafter simply referred to as wire 4 for simplicity, has a square cross-section, as do the slots 6' and 6''. In general, both wire 4 and slots 6' and 6'' can be made with different cross-sectional shapes, such as circular ones.

[0069] Further features that may differ from those shown in the figure include the number of windings 3', 3'' and corresponding slots 6', 6'' present on each side 2', 2'' of the support 2. For example, the support 2 could be constructed with two primary windings 3' and two corresponding slots 6', and two secondary windings 3'' and two corresponding slots 6'' in an intertwined helix.

[0070] In the example shown in the figure, the support 2 has two through holes 8 and 9 aligned with the central hole 5. These holes 8 and 9 serve to accommodate the terminals 4' and 4'' of the two windings 3' and 3'', so that the terminals 4' and 4'' cantilever out from the same back side 2'' of the support 2.

[0071] Therefore, in the example shown in the figure, a single wire 4 extends from the first terminal 4', defines the first winding 3' on the front side 2' of the support 2, crosses the support 2 in the transition zone 7, defines the second winding 3'', and terminates at the second terminal 4''. Notably, slots 6' and 6'' have radial segments 10 and 11, respectively, which guide the wire 4 from slots 6' and 6'' toward holes 8 and 9.

[0072] The electrical component 1 shown in the figure can be used, for example, as the rotor of an electronic motor.

[0073] In general, the support 2 does not necessarily have to be a disk shape with flat sides 2, 2'', but can have a convex or conical shape, for example, and can be applied in different fields such as the manufacture of sensors, actuators, measuring tools, and more, in addition to the manufacture of electronic motors.

[0074] Figure 4 shows a left front perspective view of a winding machine 20 according to the present invention, which implements the claimed method for the automated manufacturing of an electrical component 1. In the example shown in the figure, the machine 20 is self-supporting.

[0075] Machine 20 includes: - A supply unit 21 configured to supply the wire 4, preferably pre-tensioned to a nominal tension value. - A work station 22 on which the support 2 is restrained and windings 3' and 3'' are formed. - A movable unloading station 23 for removing the completed electrical component 1, i.e., electrical component 1 with windings 3', 3''.

[0076] The supply unit 21 is adjacent to the work station 22, specifically located above and slightly behind the work station 22. The work station 22 is further above the unloading station 23, which includes a tray 24 from which the completed electrical components 1 are dropped, and the tray 24 moves towards the unloading zone on the track 25.

[0077] Figure 5 is an enlarged view of Figure 4, specifically showing the supply unit 21 and the work station 22. The supply unit 21 is fixed to the support structure 26 of the machine 20 and includes a carriage 27 that can reciprocate in a direction parallel to the axis X of the work station 22, which in this example is the horizontal axis. The translation of the carriage 27 is controlled by at least one worm screw type actuator 28. An arm 29 extends from the carriage 27 toward the work station 22. A wire guide tube 30 is cantilevered on the arm 29 and configured to be oriented vertically and horizontally, i.e., perpendicular to the axis X and parallel to the axis X. As described below, the wire guide tube 30 accommodates the wire 4 from above and directs it appropriately toward the support 2 during processing. In particular, the wire guide tube 30 is rotatably mounted on a pin 29' that cantilevered from the arm 29 (Figure 6) and can rotate 180° between a vertical position and a horizontal position. However, it should be noted that the horizontal position of the wire guide tube 30, i.e., the position parallel to axis X, makes it possible to create terminals 4' and 4'' of the windings 3' and 3'' of the electrical component 1 shown in Figures 1-3, and the vertical position of the wire guide tube 30, i.e., the position perpendicular to axis X, makes it possible to create spiral windings 3' and 3'' on the support 2.

[0078] Figure 6 is a right-front perspective view of work station 22. Referring to Figures 5 and 6, work station 22 includes: - A fixed spindle 31 is attached to the structure 26 and is driven by a motor 32 to impart rotation around axis X to the drive shaft 33 of the same spindle 31. In the example shown, the drive between the motor 32 and the fixed spindle 31 is belt driven. -A first flange retaining carriage 34 is provided on the side of the fixed spindle 31 and has a first wire guide flange 49 (which can also be defined as a wire guide cap 49), which is mounted coaxially with the drive shaft 33 and is reciprocally movable along axis X on the drive shaft 33, in particular on the track 37. The wire guide flange 49 is spiral or helical and is used to guide the movement of the pressing roller 53 and the insertion of the wire 4 into a slot 6' provided on the front side 2' of the support 2. - A restraint mechanism 35 (shown in Figure 7B) for restraining the support 2 on the drive shaft 33, and the support 2 is coaxial with axis X. -A tailstock spindle 36 is constrained to a structure 26 and movable relative to a track 37, and moves by thrust applied by an actuator 38 provided on the same tailstock spindle 36 in directions toward and away from the fixed spindle 31. The tailstock spindle 36 is also driven, and reference numeral 39 indicates each electric motor arranged in direct drive. The tailstock spindle 36 includes a drive shaft 40 that is opposite the drive shaft 33 of the fixed spindle 31 and coaxial with it about axis X. - A gripper 41 integrated with the drive shaft 40 of the tailstock spindle 36, configured to restrain the terminals 4', 4'' of the windings 3', 3''. - On the tailstock spindle 36 is a second flange retaining carriage 42 equipped with a second wire guide flange 50 (which can also be defined as a wire guide cap 50), the second carriage 42 being coaxial with the drive shaft 40 and reciprocating along axis X on the drive shaft 40, the second wire guide flange 50 being spiral or helical and used to guide the movement of the pressing roller 53 and the insertion of the wire 4 into the slot 6'' provided on the second side 2'' of the support 2. - A unit 43 for guiding and inserting wires 4 into slots 6' and 6'' of the support 2, the unit 43 is constrained to the support structure 26 and is triaxially movable, allowing insertion between a first wire guide flange 49 and the support 2 being processed, and between a second wire guide flange 50 and the support 2 being processed, and in cooperation with the wire guide flanges 49 and 50 to obtain proper insertion of wires 4 into slots 6' and 6'' of the support 2. - A pincer assembly 44 for cutting wire 4.

[0079] As shown in Figure 6, the drive shaft 33 of the fixed spindle 31 is equipped with a seat 45 into which the wire guide tube 30 is inserted when the drive shaft 33 is fixed, that is, when it is neither rotating nor translating around axis X.

[0080] Figure 7A shows a top perspective view of the work station during the initial phase of the method according to the present invention. An external manipulator (not shown) transports the support 2 to the position shown in the figure, with its front side 2' facing the flange-holding carriage 34, and in particular, the support 2 is key-coupled to the drive shaft 33 of the fixed spindle 31. The key-coupled support 2 to the drive shaft 33 is performed by a restraining mechanism 35 (shown in Figure 7B), which operates on commands from each actuator. Subsequently, the tailstock spindle 36 is displaced toward the fixed spindle 31, and the drive shaft 40 comes into contact with the rear side 2'' of the support 2, reaching a position where the support 2 is pressed between the two drive shafts 33 and 40.

[0081] The supply unit 21 is lowered so that the arm 29 and pin 29' are aligned with the height of the support 2, and the horizontally positioned wire guide tube 30 is inserted into a seat 45 formed on the drive shaft 33 of the fixed spindle 31. Thus, the arm 29 and wire guide tube 30 are displaced toward the support 2, and as a result, the wire guide tube 30 inserts the terminal 4' of the wire 4 into a hole 9 present in the support 2. Thus, the terminal 4' protrudes from the support 2 in the opposite direction to the wire guide tube 30. At this point, the gripper 41 integrated with the drive shaft 40 of the tailstock spindle 36 intervenes. The gripper 41 is operated so that the jaws 41' close over the terminal 4', restraining the jaws 41' to prevent the wire 4 from slipping out of the support 2 during winding. The jaws 41' are hinged to the drive shaft 40 and are operable by command.

[0082] In this configuration, the drive shafts 33 and 40 are fixed and do not rotate around axis X. The flange retaining carriages 34 and 42 are separated from the support 2, allowing for the intervention of the gripper 41 on the one hand, and movement on the other hand for insertion of the wire guide tube 30 into the seat 45 and insertion of the terminal 4' into the hole 9 in the support 2.

[0083] Figure 7B shows a work station 22 with the same configuration as shown in Figure 7A, but is a cross-sectional view considered on a vertical plane passing through axis X.

[0084] Notably, the gripper 41 is located inside the drive shaft 40 of the tailstock spindle 36. The gripper 41 includes a control shaft 41'' within the drive shaft 40 and is movable along axis X relative to the drive shaft 40 to open and close the jaws 41'.

[0085] The wire guide tube 30 comprises two parallel rollers 30' and 30'', which together define the path of the wire 4. In particular, the wire 4 extends between rollers 30' and 30'' and can be wound around a portion of either of the two rollers 30' and 30'' to form a curve.

[0086] The restraint mechanism 35, which is responsible for restraining the support 2 on the drive shaft 33 of the fixed spindle 31 throughout the entire duration of the work cycle, includes two levers 46, 47 hinged to the drive shaft 33. Each lever includes a hooked end that can be inserted into the central hole 5 of the support 2. In the configuration shown in Figure 7B, the levers 46, 47 traverse the central hole 5 of the support 2 and are opened wide, with the hooked ends forming an undercut with the edge of the hole 5. This position is the normal position of the levers 46, 47. Releasing the levers 46, 47 to release the support 2 and allow it to fall onto the tray 24 by gravity is performed by an actuator in the drive shaft 33. This actuator is a control rod 48 coaxial with the drive shaft 33 and is slidable between a retracted position and an advanced position within its corresponding seat. In the retracted position shown in Figure 7B, the control rod 48 does not contact the levers 46, 47, and the levers remain wide open. In the forward position, the control rod 48 wedge-shaped into the space between the levers 46 and 47, thereby bringing the levers 46 and 47 closer together and disengaging each hooked end from the edge of the central hole 5 of the support 2. To maintain the normal engaged position of the levers 46 and 47, they are preferably subjected to the thrust of an elastic element, such as a helical spring provided on each pin of the levers 46 and 47.

[0087] Figure 8A is a right-hand perspective view of the work station 22 at a later point in the work cycle. The configuration shown in Figure 8A differs from those shown in Figures 7A and 7B in that the wire guide tube 30 is moved rearward into the seat 45 and rotated 90° counterclockwise around the pin 29' to take a vertical position, oriented the wire 4 radially with respect to axis X and support 2. The movement of the wire guide tube 30 causes local deformation of the wire 4, so that a segment of the wire 4 becomes parallel to the radial segment 10 of the slot 6' located on the front side 2', and as a result becomes insertable. The drive shafts 33 and 40 are fixed.

[0088] Figure 8B is a cross-sectional view considered on a vertical plane passing through axis X, showing the same configuration of the work station 22 as shown in Figure 8A. The end 4' of the wire 4, while constrained between the jaws 41'' in the gripper 41, passes through the hole 9 in the support 2, bends and enters the wire guide tube 30, then passes through rollers 30' and 30'' toward the supply unit 21. At this point, all components of the work station 22 are stationary.

[0089] Figure 8C shows the same configuration in a left perspective view, allowing for a clearer confirmation of the closed position of the jaws 41' of the gripper 41 that restrain the terminal 4' of the wire 4.

[0090] Figure 9 is a cross-sectional view considered on a vertical plane passing through axis X, showing the configuration of the work station 22 after the configuration shown in Figures 8A-8C, and corresponding to the initial phase of creating the first winding 3'.

[0091] In particular, in Figure 9, the second flange retaining carriage 42 on the tailstock spindle 36 side is translated on the drive shaft 40 and moved to the end stop, so that the second wire guide flange 50 is in contact with the rear side 2'' of the support 2. In this position, the drive shaft 40 and the second wire guide flange 50 rotate integrally with the support 2 around axis X. On the opposite side of the support 2, the first flange retaining carriage 34 on the fixed spindle 31 side is translated on the drive shaft 33 and moved to the end stop, so that the first wire guide flange 49 is located laterally to the front side 2' of the support 2, but not in contact with the support 2. In fact, there is still a minimum clearance between the front side 2' of the support 2 and the first wire guide flange 49 that is sufficient to prevent mechanical interference between the first wire guide flange 49 and the support 2 during relative rotation, as will be explained below. In this position, the drive shaft 33 rotates integrally with the support 2 around axis X, while the first wire guide flange 49 can rotate relative to the drive shaft 33 and therefore relative to the support 2.

[0092] The wire 4 remains pressed between the support 2 and the side surface of the first wire guide flange 49 facing the support 2.

[0093] As will become clear below, the configuration described above allows the support 2 to remain rotating and thus allows the wire guide flange 49 to rotate relative to the support 2, while the unit 43 provides for guiding the wire 4 and inserting it into the slot 6' located on the front side of the support 2.

[0094] Figure 10 is a right-hand perspective view of the details of the work station 22 in the configuration shown in Figure 9, i.e., the initial phase of forming the first winding 3' on the front side 2' of the support 2. Referring to the figure, the drive shafts 33 and 40 are rotated 90° counterclockwise synchronously, and as a result, the support 2 is also rotated 90°. This initial rotation moves the initial segment 51 of the first winding 3' to an angular position on axis X, making it suitable for the wire 4 to interact with the guide and insertion unit 43.

[0095] At this point, the terminal 4' of wire 4 is restrained by the gripper 41 on the drive shaft 40, and the segment of wire 4 is already inserted into the radial segment 10 of the slot 6' of the support 2, and is ready to be inserted into the rest of the slot 6' that extends spirally to the front side 2' of the support 2. Due to the aforementioned 90° rotation, the initial segment 51 of wire 4 is wound around the sector of the wire guide flange 49.

[0096] The guiding and insertion unit 43 includes an arm 52 equipped with a pressure roller 53. The guiding and insertion unit 43 is movable relative to the support structure 26 of the machine 20 by a specific actuator (illustrated but not numbered) intended to move the arm 52 in two radial directions relative to the axis X at the wire guiding flange 49. In other words, the arm 52 is radially movable toward and away from the axis X. The purpose of the pressure roller 53 is to apply an axial thrust to the wire 4, i.e., a thrust parallel to the axis X, causing it to insert into the slot 6' while the support 2 continues to rotate and move along the entire length of the slot 6'.

[0097] As shown in Figure 10, the arm 53 is moved to a position where it contacts the side surface 49' of the wire guide flange 49. During the rotation of the wire guide flange 49, the arm 52 with the pressure roller 53 moves backward, thereby moving radially away from axis X. This is because it is precisely guided by the wire guide flange 49 and acts as a cam. In practice, while forming the first winding 3', the wire guide flange 49 acts as a cam and the arm 52 acts as a drive.

[0098] In particular, the pressure roller 53 is intended to roll along the entire length of the slots 6' and 6'', and for this reason, it can be positioned relative to the support 2 such that its axis of rotation intersects radially with the axis X of the support and drive shafts 33 and 40. The pressure roller 53 moves along the entire length of the slots 6' and rolls over them by controlling the radial movement of the pressure roller 53 while the support 2 is rotating.

[0099] Figure 10 is a top and rear perspective view of a portion of a work station having a support 2, a first flange retaining carriage 34, a first wire guide flange 49, a second flange retaining carriage 42, and a second wire guide flange 50. The actuator 54 of the first wire guide flange 49 is clearly visible in this figure. It is a motor having an axis parallel to the drive shaft 33 and transmits motion to the first wire guide flange 49 via a gear 55 housed on the first flange retaining carriage 34, independently of the rotation of the drive shaft 33, and therefore independently of the rotation of the support 2.

[0100] In particular, the actuator 54 is an electronically controlled motor and is suitable for synchronously rotating the first wire guide flange 49 with respect to the drive shaft 33, and also for intermittently alternating the rotation of the first wire guide flange 49 with the stopping of the same flange 49 according to a preset time interval.

[0101] This detail causes the first wire guide flange 49 to rotate around axis X according to its own laws of motion imposed by actuator 54 while the first winding 3' is being made, guiding the pressure roller 53 to move along a trajectory corresponding to the pattern of slot 6', independently of the continuous rotation of the drive shaft 33 at a constant speed.

[0102] In other words, the method provides a way to control the radial displacement of the press roller 53 with respect to the axis X such that the slot 6' moves under the press roller 53 while the slot 6' rolls over the press roller 53 due to the effect of rotation given to the support 2. The radial displacement of the press roller 53 is given by the first wire guide flange 49, in particular by the side 49' of the first wire guide flange 49 that pushes the arm 52 backward.

[0103] Since the first wire guide flange 49 is spiral or helical, its side surface 49' has a minimum diameter and a maximum diameter: - Whenever the pressing roller 53 is in contact with the side surface 49' of the first wire guide flange 49 at its minimum diameter, the roller 53 is at the minimum distance from axis X and is above the initial segment of slot 6'. - Whenever the pressing roller 53 is in contact with the side surface 49' of the first wire guide flange 49 at its maximum diameter, the roller 53 is at its maximum distance from axis X and is above the terminal segment of slot 6' in the transition zone 7.

[0104] Figure 12 is a schematic diagram that helps to understand the above explanation. In particular, Figure 12 shows three schematic elevation views a to c of parts of the work station of electrical component 1 and winding machine 20 at three consecutive points in time while making the first helical winding 3'.

[0105] In figures a, b, and c, axis X is perpendicular to the plane of the drawing, and therefore the guide and insertion unit 43 and wire guide tube 30 are shown from the side, and the support 2 is shown from the front.

[0106] Figure 12(a) shows the machine 20 in the initial phase of forming the first winding 3'. This is the same configuration as shown in Figures 9-10. After the terminals 4' of the wire 4 are clamped by the gripper 41, the wire guide tube 30 rotates to a vertical position, inserting the segments of the wire 4 into the initial segments 10 of the slot 6', the carriages 34 and 42 are moved to the end stops, the drive shafts 33 and 40 abut against the support 2 in a position opposite each other, the second wire guide flange 50 abuts against the back side of the support 2, and the wire guide flange 49 is close to the front side 2' of the support 2 but does not abut it, rather abutting the wire 4.

[0107] The wire guiding tube 30 is moved to a position perpendicular to the axis X, i.e., it is aligned with the axis X above it. The wire 4 is partially wound around the side surface 49’ of the first wire guiding flange 49. The side surface 49’ is preferably polished to facilitate the wire 4 sliding towards the support 2 without damaging the wire 4. The pressing roller 53 is in contact with the side surface 49’ of the first wire guiding flange 49 at its minimum diameter and is thus at the point closest to the axis X.

[0108] In particular, the rotation axis of the pressing roller 53 intersects the axis X of the support 2, i.e., the shaft 53 is arranged radially. The conductive wire 4 is in contact with the slot 6’ at the contact point between the pressing roller 53 and the support 2.

[0109] At this point, the formation of the first winding 3’ is started.

[0110] Referring to Fig. 12(b), the drive shafts 33 and 40 rotate synchronously (counterclockwise in the figure) with the support 2 and the second wire guiding flange 50 at a constant rotational speed V2. The first winding 3’ of the support 2 is such that the wire 4 makes 4.25 rotations between the terminal 4’ and the transition zone 7, so the support 2 rotates 4.25 times, i.e., the drive shafts 33 and 40 make 4 rotations plus 1 / 4 rotation.

[0111] During the rotation of the support 2, the first wire guiding flange 49 is rotated by each actuator 54 via the gear 55 (Fig. 11) and makes 1 rotation within the time it takes for the support to rotate 4.25 times. As described above, this behavior of the first wire guiding flange 49 can be achieved in two ways: - Rotate the wire guiding flange 49 slower than the support 2, at a speed V49 < V2, or - Rotate the first wire guiding flange 49 at the same speed as the support 2, at a speed V49 = V2, but with an intermittent motion, and then stop the first wire guiding flange 49 for a time interval.

[0112] In the example shown in the figure, the second method was employed. The setting of the motion laws of the first wire guide flange 49 can be performed manually during the tuning phase of the machine 20, for example, by performing empirical tests, or by manually moving the first wire guide flange 49 and using the control unit of the machine 20 which has self-learning capabilities.

[0113] Regardless of the method chosen to control the rotational speed of the first wire guide flange 49, the result is that the pressing roller 53 rolls over the entire length of the slot 6', pushing the wire 4 into the slot and inserting it into the slot 6' by interference.

[0114] The insertion of the wire 4 into the slot 6 is advantageously performed without causing twisting of the wire 4 itself. The wire is pushed in by the pressure roller 53 with a force acting parallel to the axis X. As a result, the wire 4 inserted into the slot 6' does not tend to come out, does not generate mechanical stress on the support 2, and is advantageous for the quality and durability of the first winding 3'.

[0115] Figure 12(c) shows the final phase of creating the first winding 3', at which point the support 2 has completed four turns and the last quarter turn, and the wire 4 is in the transition zone 7. The first wire guide flange 49 is about to complete its one turn, and the pressing roller 53 is about to reach the maximum diameter of the first wire guide flange 49 in step 56.

[0116] The fact that the wire 4 is inserted by the pressure roller 53 without twisting the wire 4 means that the wire 4 does not tend to come out of each slot 6' during use of the electrical component 1.

[0117] Step 56, also shown in Figures 8C, 10 and 11, shows the difference between the minimum and maximum diameters of the helix defined by the first wire guide flange 49.

[0118] Once the support 2 and the first wire guide flange 49 have completed their respective rotations and come to a stop, the first winding 3' is completed, and the wire 4 is ready to cross the support 2 in the transition zone 7 and be guided to the back side 2'' of the support 2.

[0119] Figure 13 illustrates this situation, showing a front elevation view of part of the work station 22, illustrating the configuration at the point when the wire 4 is pulled by the wire guide tube 30 to the opposite side of the support 2 and crosses the transition zone 7. The wire guide tube 30 is positioned axially with respect to the rotation axis X, and possibly radially as well, to engage the wire 4 with the starting end of the slot 6'' located on the rear side 2'' of the support 2.

[0120] It should be noted that the first winding 3' is obtained by moving from the hole 9 of the support 2, i.e., the central zone, along the slot 6', and spirally toward the periphery of the front side 2'. As will be explained below, the second winding 3'' is obtained by moving in the opposite direction from the periphery of the back side 2'' of the support 2 to the hole 8 in the central zone. Thus, the start of the slot 6'' is defined by the transition zone 7, and the end is defined by the hole 8.

[0121] Figure 14 is a left-front perspective view showing the removal of wire 4 at the same moment as shown in Figure 13. In this configuration, the formation of the second winding 3'' can begin.

[0122] In the example shown in the figure, it should be noted that windings 3' and 3'' are substantially equal, i.e., the two helices defined by windings 3' and 3'' have the same geometric properties. Therefore, the second wire guide flange 50 has the same shape as the first wire guide flange 49. In Figure 14, reference numeral 50' indicates a side view of the second wire guide flange 50, and reference numeral 57 indicates the step defined between the minimum and maximum diameters of the same flange 50.

[0123] In practice, as will be evident from other figures, for example Figure 8A, the assembly formed by the second flange retaining carriage 42 and the drive shaft 40 and the second wire guide flange 50 substantially mirrors the assembly formed by the first flange retaining carriage 34 and the drive shaft 33 and the first wire guide flange 49.

[0124] Furthermore, an actuator 58 for the second wire guide flange 50 is also mounted on the second flange retaining carriage 42 and is intended to rotate the second wire guide flange 50 via a gear 59 according to the provided laws of motion.

[0125] The initiation of the formation of the second winding 3'' includes the following: - The first wire guide flange 49 is brought into contact with the front side 2' of the support 2, eliminating the gap that previously remained. - The second wire guide flange 50 is separated from the back side 2'' of the support 2, allowing for relative rotation of these elements.

[0126] The guiding and insertion unit 43 is repositioned, and the pressing roller 53 is moved above step 57 so as to contact the side surface 50' of the second wire guiding flange 50 at the minimum diameter of the second wire guiding flange 50.

[0127] At this point, the drive shafts 33 and 40 rotate synchronously, rotating integrally with the support 2 and the first wire guide flange 49. The wire 4 is pushed into the slot 6'' by the pressure roller 53.

[0128] In exactly the same way as described for the first wire guide flange 49, the second wire guide flange 50 can also be operated in two ways: - Rotate the second wire guide flange 50 at a speed slower than the support 2, such that V50 < V2, or - The second wire guide flange 50 is rotated at the same speed as the support 2, at a speed of V50 = V2, but in an intermittent motion, and then the second wire guide flange 50 is stopped at time intervals.

[0129] The latter is the preferred mode performed in the illustrated example and is set empirically or by the self-learning procedure of the electronic system of machine 20.

[0130] The combination of the support 2 and the second wire guide flange 50, along with the two rotary motors, causes the pressing roller to move along the entire length of the slot 6'', inserting the wire 4 into the slot 6'' and thus completing the second winding 3''.

[0131] Figure 15 is a left-front perspective view of the work station 22 showing the successive phases. The second winding 3'' is completed by rolling the pressure roller 53 on the slot 6'' from the periphery towards the center of the support 2, as described above, and now it is necessary to create the second terminal 4''. The tailstock spindle 36 is displaced rearward on the axis X together with the second flange retaining carriage 42, as a result a gap 60 opens between the second wire guide flange 50 and the support 2. The support remains constrained on the drive shaft 33 due to the effect of the restraint applied by the lever 47.

[0132] At this point, to facilitate the insertion of the wire 4 into the terminal segment 11 of the slot 6'' which extends radially toward axis X, the guiding and insertion unit 43 operates a second tool on the arm 52. This is a second inclined arm 61 equipped with an auxiliary cylindrical pressing element 62 for guiding the wire 4. In practice, the auxiliary pressing element 62 provides the wire 4 with a temporary winding surface, so by partially winding around the auxiliary pressing element 62, the wire 4 can be steered, resulting in it moving away from the helical segment of the slot 6'' and into the linear and radial segments 11 of the slot 6''. The auxiliary pressing element 62 remains operational throughout the entire period of the insertion of the wire 4 into the linear and radial segments 11 of the slot 6''.

[0133] Figures 16 and 17 are rear and top perspective views of the work station 22 at consecutive points in time during the formation of terminal 4''. Figure 16 shows the following interpolated points in time: - Complementary movement of the induction and insertion unit 43, - Complementing the rotation of support 2 (clockwise as shown in the figure), and - Complementary movement for repositioning the wire guide tube 30 (in addition to rotation around pin 29', the raising and lowering and displacement of pin 29').

[0134] These movements are coordinately controlled by the control unit of the machine 20 to precisely insert the wire 4 into the radial segment 11 of the slot 6''.

[0135] For example, as shown in Figure 16, the support 2 is rotated to orient the radial segment 11 of the slot 6'' vertically, thus allowing the insertion of the wire 4 in vertical movement until the unit 43 reaches the hole 9.

[0136] Alternatively, as shown in Figure 17, the support 2 is rotated to orient the radial segment 11 of slot 6'' horizontally, thus allowing the insertion of the wire 4 in horizontal movement until the unit 43 reaches the hole 9. Notably, the wire guide tube 30 is rotated to a horizontal position so that the terminal 4'' is parallel to axis X.

[0137] Figure 18 is a left front perspective view of a portion of the work station 22 of the winding machine 20 at a point in time consecutive to the formation of terminal 4'' as described with reference to Figures 16 and 17. The rotation of the drive shafts 33 and 40 is stopped, and the tailstock spindle 36 is moved backward together with the flange retaining carriage 42 to form a gap 60 into which the pincer assembly 44 is inserted. The movement of the pincer assembly is perpendicular to the axis X. The pincer assembly 44 cuts the wire 4 and completes the fabrication of terminal 4'' of the electrical component 1.

[0138] Figure 19 is an axial cross-sectional view considered on a vertical plane of the same configuration of the work station 22 as shown in Figure 18, i.e., the configuration in which the pincer assembly 44 is inserted into the gap 60 to cut the wire 4 and complete the terminal 4''. Thus, the pincer assembly is shown from the front while cutting the wire 4 at terminal 4'' with the wire guide tube positioned parallel to axis X.

[0139] Figure 20 shows front and left perspective views of the work station 22 at a point in time consecutive to the configuration shown in Figures 18 and 19. The pincer assembly 44 cuts the wire 4, and the electrical component 1 is finally completed and ready to be unloaded onto the tray 24 of the carriage 23. The removal is performed by gravity, and the control rod 48 is inserted between levers 46 and 47 to open them wide and detach the support 2.

[0140] In the example described, the first winding 3' and the second winding 3'' are substantially identical, and as a result, the wire guide flanges 49 and 50 have the same geometry. In general, windings can have different geometry, and therefore the wire guide flanges 49 and 50 can also be made in different shapes.

[0141] Furthermore, in the example shown in the figure, it is noteworthy that the electrical component 1 includes two opposing windings 3' and 3'', i.e., positioned on the opposing sides 2' and 2'' of the support 1. Generally, however, the method described is also applicable to manufacturing an electrical component 1 with a single winding. Clearly, whenever the support 2 is convex or conical, the insertion of the wire 4 into each slot is also performed by the axial movement of the unit 43 and the pressure roller 53, the unit and the pressure roller following the profile of the support surface.

Claims

1. A method for manufacturing an electrical component (1) comprising a support (2) having at least one side (2', 2''), wherein the at least one side (2', 2'') has at least one helical slot (6', 6'') that is coaxial with the axis (X) of the support (2) and extends radially or mainly radially, and at least one conductive wire (4) defining a helical winding (3', 3'') is housed in the at least one slot (6', 6''), The aforementioned method, A) Rotating the support (2) on the axis (X), B) Supplying the conductive wire (4) to the support (2), C) A pressing roller (53) is positioned to roll on the slots (6', 6''), the pressing roller having a rotation axis intersecting the axis (X) of the support (2) inserts the conductive wire (4) into the slots (6', 6''), and moves the pressing roller (53) radially with respect to the axis (X) of the support, thereby moving along the entire length of the slots (6', 6''). method.

2. The method according to claim 1, wherein Phase A is performed by constraining the support (2) on a drive shaft (33) that is coaxial with the axis (X) of the support (2) and is susceptible to rotation around the axis (X).

3. The method according to claim 1 or 2, wherein phase B is performed by a wire guide tube (30) movable relative to the support (2), and care is taken to supply the conductive wire (4) to each of the slots (6', 6'') in a trajectory tacting with the slots (6', 6'').

4. The method according to any one of claims 1 to 3, wherein phase C is performed by bringing the pressing roller (53) into contact with the wire guide flanges (49, 50), the wire guide flanges (49, 50) functioning as end stops and defining the distance between the pressing roller (53) and the axis (X) of the support (2).

5. The wire guide flanges (49, 50) are arranged coaxially with the axis (X) of the support (2) and are rotatable on the same axis (X), and the wire guide flanges (49, 50) are spiral or helical in shape and have sides (49', 50') extending between the minimum diameter portion and the maximum diameter portion. - When the pressing roller is in contact with the side surface (49', 50') of the wire guide flange (49, 50) at its smallest diameter portion, the pressing roller (53) is located at the minimum distance from the axis (X) of the support (2) and is located at the first end of the slot (6', 6''), - When the pressing roller is in contact with the side surface of the wire guide flange (49, 50) at its maximum diameter portion, the pressing roller (53) is located at the maximum distance from the axis (X) of the support (2) and is located at the second end of the slot (6', 6''), The method according to claim 4.

6. The method according to claim 4 or claim 5, wherein relative rotation is performed between the support (2) and the wire guide flanges (49, 50).

7. The rotation of the wire guide flanges (49, 50) of the support about the axis (X) is - Rotate the wire guide flanges (49, 50) slower than the support (2), or - The method according to any one of claims 4 to 6, wherein the wire guide flanges (49, 50) are controlled by intermittently rotating them at the same speed as the support (2).

8. The electrical component (1) has a first winding (3') and a second winding (3'') at mutually opposing positions on the support (2), The support is flat and has a front side (2') and a back side (2''), with a first slot (6') formed on the front side (2') and a second slot (6'') formed on the back side (2''), The support (2) has a transition zone (7) where the first slot (6') merges with the second slot (6''), Phase C is C1) The conductive wire (4) is inserted into the first slot (6') by the pressing roller (53), and the first winding (3') is formed by moving the pressing roller (53) radially with respect to the axis (X) of the support between a position proximal to the axis (X) (the starting end of the first slot (6')) and a position distal to the axis (X) (the ending end of the first slot (6')). C2) In the transition zone (7), the conductive wire (4) is placed on the support (2), and the conductive wire (4) is transported from the front side (2') of the support (2) to the back side (2'') of the support (2). C3) The conductive wire (4) is inserted into the second slot (6'') by the pressing roller (53), and the second winding (3'') is formed by moving the pressing roller (53) radially with respect to the axis (X) of the support between a distal position with respect to the axis (X) (the starting end of the second slot (6'')) and a proximal position with respect to the axis (X) (the ending end of the second slot (6'')). The method according to any one of the prior claims.

9. The method according to claim 8, wherein C1 is carried out by guiding the radial movement of the pressure roller (53) with the first wire guide flange (49), C2 is carried out by using a wire guide tube (30) that is movable relative to the support (2), and C3 is carried out by guiding the radial movement of the pressure roller (53) with the second wire guide flange (50), wherein both wire guide flanges (49, 50) are arranged coaxially with respect to the axis (X) of the support and are located opposite each other thereto, and relative rotation occurs between the support (2) and each of the wire guide flanges (49, 50) between phases C1 and C3.

10. The at least one slot (6', 6'') has radial segments (10, 11), and the insertion of the conductive wire (4) into the radial segments (10, 11) is D) This is performed by locking the support (2) with respect to the axis (X), aligning the pressure roller (53) with the axis (X) of the support (2), and rolling the pressure roller (53) on the radial segments (10, 11) of the at least one slot (6', 6''), The method according to claim 8 or claim 9.

11. An electrical component (1) obtained directly by the method described in any one of the prior claims, An electrical component (1) comprising a support (2) having at least one side (2', 2''), wherein at least one helical slot (6', 6'') is present on the at least one side (2', 2'') and is coaxial with the axis (X) of the support (2), and at least one conductive wire (4) defining a helical winding (3', 3'') is housed in the at least one slot (6', 6'').

12. The electrical component (1) according to claim 11, wherein the conductive wire (4) of the helical winding (3', 3'') is not twisted.

13. The electrical component (1) according to claim 11 or claim 12, wherein the support (2) is flat, has a first winding (3') on the front side (2'), and has a second winding (3'') on the rear side (2'').

14. The electrical component (1) according to any one of claims 11 to 13, wherein the winding (3', 3'') has terminals (4', 4'') that cantilever out from the same side (2'') of the support (2).

15. An automatic winding machine (20) for manufacturing an electrical component (1) comprising a support (2) having at least one side (2', 2''), wherein at least one side (2', 2'') has at least one helical slot (6', 6'') coaxial with the axis (X) of the support (2), and at least one conductive wire (4) defining a helical winding (3', 3'') is housed in the at least one slot (6', 6''), The winding machine (20) includes a work station (22) and a supply unit (21), the latter of which is configured to supply the conductive wire (4) to the work station (22). The work station (22) includes a first spindle (31), a corresponding first drive shaft (33), means (46, 47) for coaxially restraining the support (2) on the drive shaft (33), a first wire guide flange (49), and a pressing roller (53), The support (2) and the first drive shaft (33) are rotatable around the axis (X) of the support (2), The pressing roller (53) is positionable with respect to one side (2') of the support (2) so that it can roll on at least one slot (6'), and is susceptible to radial displacement with respect to the axis (X) of the support (2), The wire guide flange (49) is provided coaxially with the first drive shaft (33), and is susceptible to translational influences between a position proximal to the support (2) and a position distal to the support (2) along the first drive shaft (33), and is susceptible to synchronous rotation with the first drive shaft (33) and / or relative rotation with respect to the first drive shaft (33), The first wire guide flange (49) is spiral or helical in shape, and the insertion of the conductive wire (4) into the slot (6') is performed by rotating the first drive shaft (33) together with the support (2), causing the pressing roller (53) to roll on the slot (6'), and simultaneously pushing the conductive wire (4) into the slot (6'), thereby causing the pressing roller (53) to move radially relative to the axis (X) of the support (2), and the radial movement of the pressing roller (53) is guided by the side surface (49') of the first wire guide flange (49). Automatic winding machine (20).

16. The automatic winding machine (20) according to claim 15, wherein phase A of the method according to claim 1 is performed on the first spindle (31) and the first drive shaft (33), phase B of the method according to claim 1 is performed on the supply unit (21), and phase C of the method according to claim 1 is performed by rolling the press roller (53) over the entire length of the slot (6') with the conductive wire (4) inserted between the slot (6') and the press roller (53), and translating the press roller (53) radially on the support (2) with respect to the axis (X).

17. Automatic winding machine (20) according to claim 15 or 16, wherein the supply unit (21) includes a wire guide tube (30) movable with respect to the support body (2) and the axis (X) of the first drive shaft (33), and the wire guide tube (30) is capable of directing the conductive wire (4) to the support body (2) provided on the first drive shaft so as to supply the conductive wire (4) perpendicular to the side surface (2') of the support body (2) and / or radially or tangentially to the slot (6').

18. The automatic winding machine (20) according to claim 17, wherein the supply unit (21) is a three-axis unit.

19. The means (46, 47) for coaxially restraining the support (2) on the drive shaft (33) includes two levers (46, 47) pivotally supported on the head of the first drive shaft (33) and operable to engage with the inner edge (5) of the support (2), according to any one of claims 15 to 18, the automatic winding machine (20).

20. Automatic winding machine (20) according to claim 19, comprising a control rod (48) for controlling the levers (46, 47), wherein the control rod (48) is located in and coaxial with the first drive shaft (33), and is translatable between a retracted position and an extended position, in the retracted position the control rod (48) does not engage with the levers (46, 47), the levers engage with the support (2) and restrain them on the first drive shaft (33), and in the extended position the control rod (48) is inserted between the levers (46, 47) and the levers are disengaged from the support (2).

21. The automatic winding machine (20) according to any one of claims 15 to 20, wherein the work station (22) includes a first flange retaining carriage (34) into which the first drive shaft (33) is inserted, the first wire guide flange (49) is provided on the first flange retaining carriage (34), and a corresponding actuator (54) is provided to control the rotation of the first wire guide flange (49) independently of the rotation given to the first drive shaft (33) by the first spindle (31), the first flange retaining carriage (34) is translatable along the first drive shaft between a retracted position and a forward position, in the retracted position the first wire guide flange (49) is away from the support (2) constrained on the first drive shaft (33), and in the forward position the first wire guide flange (49) is in contact with the support (2) constrained on the first drive shaft (33) ) Automatic winding machine (20) according to any one of claims 15 to 20.

22. The automatic winding machine (20) according to any one of claims 15 to 21, wherein the side surface (49') of the first wire guide flange (49) extends between the minimum diameter portion of the first wire guide flange (49) and the maximum diameter portion of the first wire guide flange (49), and the side surface (49') of the first wire guide flange (49) defines an end stop in the radial displacement of the pressing roller (53) with respect to the axis (X) of the support (2).

23. Automatic winding machine (20) according to any one of the preceding claims 15 to 22, comprising a unit (43) configured to guide and insert the conductive wire (4) into the slot (6') of the support (2), wherein a pressing roller (53) is provided on the unit (43), and the unit (43) is susceptible to displacement on three axes, enabling the pressing roller (53) to be inserted between the first wire guide flange (49) and the support (2) with the axis of rotation of the pressing roller (53) transverse or intersecting with the support (2) and the axis (X) of the first drive shaft (33).

24. Automatic winding machine (20) according to claim 23, wherein the unit (43) includes an arm (52), the pressing roller (53) is provided on the arm (52), and the arm (52) is movable such that the pressing roller (53) remains in contact with the side surface (49') of the first wire guide flange (49) while the first wire guide flange (49) is rotating.

25. An automatic winding machine (20) according to any one of claims 15 to 24, comprising a pincer assembly (44) that is movable relative to the axis (X) and operable to cut the conductive wire (4).

26. The support (2) has a front side (2') and a back side (2''), and each side (2', 2'') has at least one slot (6', 6''), a first winding (3') is formed in the slot (6') of the front side (2'), and a second winding (3'') is formed in the slot (6'') of the back side (2''), The first spindle (31) is stationary, and the winding machine (20) further includes a second spindle (36) defined as a tailstock spindle (36), a corresponding second drive shaft (40), and a second wire guide flange (50), which are positioned on the opposite side of the first spindle (31), the first drive shaft (33), and the first wire guide flange (49) with respect to the support (2) which is constrained to the first drive shaft (33). The first drive shaft (33) and the second drive shaft (40) are coaxial with respect to the axis (X) of the support (2) and are rotatable about the same axis (X), the second drive shaft is translatable along the axis (X) between a forward position and a retracted position, in the forward position the second drive shaft (40) abuts against and / or the support (2) constrained by the first drive shaft (33), and in the retracted position the second drive shaft (40) is away from the support (2) constrained by the first drive shaft (33), and a gap (60) into which the supply unit (21) and the pressing roller (53) can be inserted is defined between the support (2) and the second drive shaft (40). An automatic winding machine (20) according to any one of claims 15 to 25.

27. The automatic winding machine (20) according to claim 26, wherein the second wire guide flange (50) is provided coaxially with the second drive shaft (40), and is susceptible to translational influences between a position proximal to the back side (2'') of the support (2) on the second drive shaft (40), and is susceptible to synchronous rotation with the second drive shaft (40) and / or relative rotation with respect to the second drive shaft (40).

28. The work station (22) includes a second flange retaining carriage (42) into which the second drive shaft (40) is inserted, the second wire guide flange (49) is mounted on the second flange retaining carriage (42), and a corresponding actuator (58) is provided to control the rotation of the second wire guide flange (50) independently of the rotation given to the second drive shaft (40) by the tailstock spindle (36), and the second flange retaining carriage (42) is positioned between a retracted position and a forward position. Automatic winding machine (20) according to any one of claims 26 to 27, wherein the second wire guide flange (50) is translatable along the second drive shaft (40) in between, and in the retracted position, the second wire guide flange (50) is away from the support (2) constrained on the first drive shaft (33), and in the forward position, the second wire guide flange (50) is in contact with the rear side (2'') of the support (2) constrained on the first drive shaft (33) and is on the opposite side (2') from which the first wire guide flange (49) acts.

29. The second wire guide flange (40) is spiral or helical, and is the same as or different from the first wire guide flange (49), and the insertion of the conductive wire (4) into the slot (6'') on the back side (6'') of the support (2) is performed by rotating the second drive shaft (33) together with the support (2) and the first drive shaft (33), causing the pressing roller (53) to roll on the slot (6''), and simultaneously pushing the conductive wire (4) into the slot (6''), thus giving the pressing roller (53) radial movement of the support (2) with respect to the axis (X), The radial movement of the pressing roller (53) is guided by the side surface (50') of the second wire guide flange (50). An automatic winding machine (20) according to any one of claims 26 to 28.

30. The automatic winding machine (20) according to claim 29, wherein the side surface (50') of the second wire guide flange (50) extends between the minimum diameter portion of the second wire guide flange (50) and the maximum diameter portion of the second wire guide flange (50), and the side surface (50') of the second wire guide flange (50) defines an end stop in the radial displacement of the pressing roller (53) with respect to the axis (X) of the support (2).

31. - Phase A of the method according to claim 1 is performed by rotating the assembly formed by the first spindle (31) and the first drive shaft (33), the tailstock spindle (36) and the second drive shaft (40), and the support (2), - Phase B of the method according to claim 1 is performed in the supply unit (21), - Phase C of the method according to claim 1 is performed by rolling the press roller (53) over the entire length of the slot (6'') on the back side (2'') of the support (2) with the conductive wire (4) inserted between the slot (6'') and the press roller (53), and translating the press roller (53) radially on the support (2) with respect to the axis (X), Automatic winding machine (20) according to claim 29 or claim 30.

32. The automatic winding machine (20) according to any one of claims 26 to 31, wherein the supply unit (21) is movable to overlap the conductive wire (4) on the support (2) and position it between the end of the first winding (3') and the beginning of the second winding (3'').

33. An automatic winding machine (20) according to any one of claims 26 to 32, comprising a gripper (41) configured to restrain the terminal (4') of the conductive wire at the head of the second drive shaft (40).

34. The gripper (41) is integrated with the second drive shaft (40), and includes a jaw (41') and a control shaft (41'') provided on the second drive shaft (40). The control shaft (41'') is located within the second drive shaft (40) and is coaxial, and is susceptible to translational influences on the axis (X), The jaws (41') are movable so as to move toward and away from each other in response to stress applied by the control shaft (41''), and restrain and release the terminals (4') of the conductive wire (4) that cantilever from or pass through the support (2). The automatic winding machine (20) according to claim 33.

35. The automatic winding machine (20) according to any one of the preceding claims, wherein each of the wire guide flanges (49, 50) is rotated by its actuator at a rotational speed lower than or intermittently driven at the same rotational speed as each of the drive shafts (33, 40).

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